RS2 50 chasis ANG.indd

ENGLIS
Index
Chassis
INTRODUCTION
MANUAL UPDATES
6
SYMBOLOGY USED IN THE MANUAL
7
ABBREVIATIONS USED IN THE MANUAL
8
GENERAL WORK RULES
9
RECOMMENDATIONS
10
GETTING TO KNOW THE MOTORBIKE
MAINTENANCE OPERATIONS
15
TECHNICAL SPECIFICATIONS
15
UNPACKING
18
APPARANCE
18
DATA FOR IDENTIFICATION
18
ANTI-TAMPERING LABEL
18
IDENTIFYING THE MAIN ELEMENTS
19
CONTROLS
20
KEYS
20
STEERING LOCK
20
SIDE STAND
20
INSTRUMENT PANEL
21
TYRES
22
CHECKING TYRE PRESSURES
22
FUEL TANK
22
COOLANT
23
REPLACING COOLANT
23
ENGINE OIL
24
TRANSMISSION OIL
24
BRAKE FLUID
25
ADJUSTING THE MINIMUM REV SETTING
25
ADJUSTING TRANSMISION CHAIN TENSION
26
1
Index
Chassis
DISASSEMBLY
2
1. REAR VIEW MIRRORS
28
2. FRONT HEADLIGHT HOLDER
28
3. FRONT SIDE COVERS
29
4. SEAT
29
5. NUMBER PLATE HOLDER
30
6. REAR COVER
30
7. FRONT MUDGUARD
30
8. FUEL TANK
31
9. FUEL TANK PROTECTOR
31
10. HANDLEBARS
32
11. STEERING
32
12. CLUTCH LEVER
33
13. FRONT BRAKE CYLINDER
33
14. FRONT HEADLIGHT
34
15. FRONT INDICATOR LIGHTS
34
16. REAR LIGHT
35
17. REAR INDICATOR LIGHTS
35
18. INSTRUMENT PANEL
36
19. TURN INDICATOR REGULATOR
36
20. CONTACT RELAY
37
21. CONTROL UNIT (CDI)
37
22. BATTERY
38
23. OIL SENSOR
38
24. OIL TANK
38
25. AIR FILTER
39
26. FUEL TRANSMISSION/OIL MIXER
39
27. “AIS” SYSTEM
39
28. EXHAUST
40
29. SILENCER
40
30. RADIATOR
41
31. CARBURETTOR
41
32. GEAR CHANGE LEVER
42
33. REAR BRAKE LEVER
42
34. SIDE STAND
43
ENGLIS
Index
Chassis
35. REAR BRAKE CYLINDER
43
36. REAR BRAKE CALLIPER
43
37. ENGINE
44
38. REAR WHEEL
45
39. CHAIN PROTECTOR
45
40. DRIVE CHAIN
45
41. SHOCK ABSORBER
46
42. SWING ARM
46
43. FRONT WHEEL
47
44. FRONT BRAKE CALLIPER
47
45. FRONT BRAKE DISK
47
46. SPEED SENSOR
48
47. FRONT FOOTRESTS
48
48. REAR FOOTRESTS BRACKETW
48
48. TIGHTENING TORQUES
49
3
ENG
Introduction
5
Introduction
Chassis
This workshop manual contains the main electromechanical checks, as well as the essential general
checks and the fitting of components supplied separately, designed to prepare the factory-new moped for delivery.
It is very important to adhere strictly to the instructions set out in the manual. Interventions carried
out superficially, or worse still, omitted entirely, may result in personal injury to the user, damage to
the machine, etc., or may simply result in disagreeable complaints.
N.B.: Rieju, S.A. reserves the right to make changes at any time, without prior notification.
For any enquiry, or for further complimentary information, please call the Rieju S.A. Aftersales Service.
MANUAL UPDATES
Updates will be sent within a reasonable period of time. Each new CD-Rom will update previous
information.
The contents list will be updated if the modifications and/or variations in the pages affect the ability
to consult the manual.
IMPORTANT! This series of workshop manuals should be considered as work instruments in themselves and can only maintain their “value” over time if they are kept constantly up to date.
6
ENGLIS
Introduction
Chassis
SYMBOLOGY USED IN THE MANUAL
CAUTION! Recommendations and precautions regarding rider safety and motor vehicle integrity.
WARNING!
Situations entailing the risk of personal injury to maintenance or repair mechanics, other workshop personnel or third parties, or damage to environment,
vehicle or equipment.
FIRE HAZARD
Indicates operations which may constitute a fire hazard.
RISK OF EXPLOSION
Indicates operations which may constitute a risk of explosion.
C
IC
OXXI
TTO
TOXIC
Indicates a possibility of intoxication or inflammation of the upper respiratory
tract.
MECHANICAL MAINTENANCE
Operations to be performed only by an expert mechanic.
ELECTRICAL MAINTENANCE
Operations be performed only by an expert electrical / electronic technician.
NO!
Operations to be absolutely avoided.
SERVICE MANUAL
Indicates information which may be obtained by referring to said manual.
SPARE PARTS CATALOGUE
Indicates information which may be obtained by referring to said catalogue.
7
Introduction
Chassis
ABBREVIATIONS USED IN THE MANUAL
F
Pr Tr
Figure
Tightening torque
P
Ap
S
Page
Paragraph
Section
Es
T
Diagram
Table
Tr
Screw
Note:
The letter Tr in the illustrations refers to retaining or adjusting screws.
The number following this letter refers to the number of the same type of
screw in the unit or component described and illustrated. Letters not followed by a number indicate a single screw . In case of different screws being
referred to in the illustration, the letter Tr is followed by a number and a
small letter , for instance: (Tr4a).
Unless otherwise specified, units and components are reassembled by proceeding in the reverse order of removal.
8
ENGLIS
Introduction
Chassis
GENERAL WORK RULES
• The advice, recommendations and warnings given hereafter are aimed at ensuring
maximum work safety as well as at considerably reducing the risk of accidents, personal
injury, equipment damage and idle times. They should therefore be strictly adhered to.
ADVICE:
• Only use quality tools and equipment.
• Only use equipment conforming to EU Directives for lifting the vehicle.
• During operations, always keep tools and equipment at hand, possibly laying them out
according to the sequence in which they are to be used. Absolutely avoid putting them on
the vehicle itself, out-of-sight or in poorly accessible places.
• Always keep the work area clean and tidy.
• When tightening screws or nuts, start with the larger diameter or inner fasteners, and
tighten them in progressive “pulls” in accordance to a “criss-cross” pattern.
• Preferably use open-end box wrenches by “pulling” and not “pushing”.
• Adjustable wrenches (F-1) should only be used in case of emergency, i.e. when a properly
sized wrench is not available. They should preferably not be used as the movable jaw tends
to open thus risking damaging or not properly tightening the bolt to the correct torque. In
any case, when using an adjustable wrench, take care to proceed as shown in Figure 1.
• Except for occasional customers, always make out and deliver to the customer a work
sheet specifying the operations performed, with notes as to any future checks eventually
required.
F-1
9
Introduction
Chassis
RECOMMENDATIONS
• Before carrying out any operation on the vehicle, wait for all parts to cool down.
• For operations requiring two mechanics, make sure that the various steps to be performed by each of them are clearly defined and coordinated beforehand.
• Make sure that each component has been properly fitted before proceeding with the next
one.
• Lubricate all parts (where applicable) before reinstalling them.
• Gaskets, O-rings, circlips and split pins must be replaced at every refitting.
• The torque settings specified in the manuals refer to the “final torque”, which must be
attained progressively by steps.
• Loosen and tighten aluminium alloy parts (covers) only after the engine has fully cooled
down.
• Only use screwdrivers with sizes suitable to the screws to be loosened or tightened.
• Work in a comfortable position and ensure that the vehicle is stable.
• Never use a screwdriver as a lever or chisel.
• Never use pincers to loosen or tighten screws or nuts because, in addition to
not providing a sufficient clamping force, they may also damage the screw
head or nut hexagon.
• Never tap the wrench with a hammer or other similar tools to loosen or tighten screws and nuts (F. 2).
• Never attempt to increase the lever arm by fitting a tube into the wrench
(F-3).
F-2
10
F-3
ENGLIS
Introduction
Chassis
Never use open flames for any reason.
Never leave open containers or containers not suitable for holding fuel in passageways,
close to heat sources, etc
Never use petrol to clean the vehicle or the floor of the workshop. Always use low flash
point solvents to clean the vehicle components.
Never suck from or blow into the fuel pipe.
When welding, make sure that there are no flammable liquids in the vicinity. Always remove the tank, even if completely empty, and disconnect the negative cable (-) from the
battery.
Never leave the engine running in closed or poorly ventilated areas.
Before any servicing, make sure that the motorbike is perfectly stable.
The front wheel should preferably be anchored to the equipment (A/F-4) integral with the
lifting board.
F-4
11
ENG
Getting to know the motorbike
13
Rieju chassis
14
Chassis
MAINTENANCE OPERATIONS
Check the brake system
Check the transmission oil level
Check chain tension and wear
Check suspensions
Check, adjust and grease controls and cables
Clean and grease air filter
Check and adjust carburettor
Check and adjust or change spark plug
Check chassis – plastics nut and bolt tightness
Check electrical system
Check segment wear
Check radiator water level
Check exhaust system
Check oil pump functioning
Check battery condition and terminals
ENGLIS
Rieju chassis
Chassis
1ST SERVICE
1.000 KMS.
2ND SERVICE
3.000 KMS.
·
·
·
·
·
·
·
·
·
·
·
·
·
·
·
·
·
·
Change
SER. EVERY
5.000 KMS.
·
·
·
·
·
·
·
·
·
·
·
·
·
·
Change
·
·
TECHNICAL SPECIFICATIONS
Dimensions
MATRIX
NAKED
Total length
Total width
Total height
Seat height
Distance between axles
1900 mm.
620 mm.
1060 mm.
800 mm.
1300 mm.
1900 mm.
725 mm.
1060 mm.
800 mm.
1300 mm.
Dry weight
MATRIX
NAKED
109 kg.
102 kg.
Engine
Type
Number of gears
Make
Model
Cylinders, arrangement
Cubic capacity
Diameter x stroke
Starter system
Lubrication system
Type of oil
2 stroke
6 gears
Minarelli
AM 6 (EU 2)
1 forward tilting
49.7 c.c.
40.3 x 39 mm.
Electrical
Pumped
2 stroke injection
15
Rieju chassis
Chassis
Transmission oil
SAE 10W 40
820 c.c.
Type
Quantity
Air filter
Wet-type sponge rubber
Fuel
95 octane lead-free petrol
10 L.
Type
Tank capacity
Carburettor
Dellorto PHBN 16 HS
Spark plug
NGK BR 9 ES
0,6 - 0,7 mm.
Type
Electrode gap
Clutch type
Multi-disk in oil bath
Primary transmission
Clutch crown wheel
Drive pinion
Transmission ratio
Z = 71
Z = 20
1: 3,55
Secondary transmission
Engine output pinion
Drag plate
Transmission ratio
Chain
Z = 11
Z = 47
1: 4,27
420 SR x 126 links
GEARCHANGE
Speed
1ª
2ª
3ª
4ª
5ª
6ª
16
Primary shaft
Z = 12
Z = 16
Z = 19
Z = 22
Z = 24
Z = 25
Secondary shaft
Z = 36
Z = 33
Z = 29
Z = 27
Z = 25
Z = 24
Gear ratio
1: 3,00
1: 2,06
1: 1,53
1: 1,23
1: 1,04
1: 0,96
Output ratio
1: 44,40
1: 31,20
1: 23,14
1: 18,60
1: 15,80
1: 14,56
ENGLIS
Rieju chassis
Chassis
Suspension:
Front
SHOWA inverted forks
Ø 35mm stems.
Oil capacity: 210 c.c. per stem
Type of oil: SAE 10W
PAIOLI forks
Ø 37mm bars.
Oil capacity – 380 c.c. per stem
Type of oil: SAE 10W
Rear
MONO-SHOCK shock absorber
Brakes
Front
Rear
Ø 280 mm disk brakes.
Ø 220 mm disk brakes.
Tyres
Front
Rear
100/80 - 17, with Tubeless, 1’8 kg/cm2
130/70 - 17, with Tubeless, 2’0 kg/cm2
Electrical equipment
Ignition
Generator
Ignition advance
Battery
Fuse
Electronic 12V 95W
Ducati
20º 1’4mm. before P.M.S.
12V 3 Ah
7,5 Ah
Bulb voltage and wattage
MATRIX
NAKED
Headlight
Rear sidelight
Turn indicators
Speedometer/milometer wiring
12V 55W H3
Leds
12V 10W
Leds
12V 60 / 55W H4
Leds
12V 10W
12V 1,2W
17
Rieju chassis
Chassis
UNPACKING
• Unpack the moped by following the instructions set out on the packing itself; the latter
being then disposed of in accordance with existing regulations.
APPARANCE
• Check visually that all the plastic material components are correctly fitted and that the
machine has no visible scratches, marks, etc.
DATA FOR IDENTIFICATION
Engine identification number
• Data for identifying the engine (A/F-1) can be
seen on the left hand crankcase.
A
F-1
Machine identification number
• The machine identification number (B/F-2) is
stamped onto the steering arm. This identification number is used to identify the moped.
B
F-2
ANTI-TAMPERING LABEL
Contains the machine identification details
(B/F-3) envisaged by Directive 97/24/CE.
It is essential to indicate the machine identification details when ordering spare parts.
This label must not be substituted or modified
in any way.
It is located on the right hand side of the swinging arm.
B
B
F-3
18
ENGLIS
Rieju chassis
Chassis
IDENTIFYING THE MAIN ELEMENTS
(Left hand side)
1. Headlight
2. Oil tank
3. Battery
4. Gear pedal
5. Fuel tank cap
3
5
1
2
4
F-4
IDENTIFYING THE MAIN ELEMENTS
(Right hand side)
6. Rear brake pedal
7. Passenger footrests
8. Number plate light and
plate holder
8
7
6
F-5
19
Rieju chassis
Chassis
CONTROLS
Controls/instruments
4
1. Main switch
2. Clutch lever
3. Turn signal switch
4. Instrument panel
5. Manual starter lever
6. Front brake cylinder
7. Front brake lever
8. Throttle grip
9. Horn button
10. Dipswitch
1
6
10
7
9
2
5
3
8
F-6
KEYS
• The machine is supplied with two keys with a number code that enables:
- The starter switch to be activated.
- The steering to be locked.
STEERING LOCK
Activation: With the handlebars turned to the left, insert the key fully and turn it to
the left.
• Deactivation: Turn the key to the right.
SIDE STAND
• Check that the side stand is properly fitted and moves correctly. It is also recommended
that the retaining system, consisting of traction springs, be regularly checked.
20
F-7
ENGLIS
Rieju chassis
Chassis
INSTRUMENT PANEL
1- Turn indicator warning light
This warning light flashes when the turn indicator switch is moved to the left or to the
right.
2- Coolant temperature warning light
This warning light comes on when the coolant temperature is too high. When the warning light comes on, stop the engine immediately.
3- Neutral position “N” warning light
This warning light comes on when the transmission is in neutral position.
4- Oil level warning light
This warning light comes on when the oil level is low.
5- Main beam warning light
This indicator lights up when the main headlight beam is in use.
6- Fuel level warning light
This warning light comes on when the petrol level is low.
1
MATRIX RS2 version.
5
6
3
4
2
F-8
1
6
5
NAKED version.
3
F-9
21
Rieju chassis
Chassis
TYRES
Dimensions
100/80 - 17, with Tubeless, 1’8 kg/cm2
130/70 - 17, with Tubeless, 2’0 kg/cm2
CHECKING TYRE PRESSURES
Tyre pressures must be checked and adjusted when the tyres are cold.
Wheel
bar
FRONT
1,8 kg / cm2
REAR
2,0 kg / cm2
FRONT
REAR
F-10
FUEL TANK
Lift the cover (A/F-11), open the cap using the key, and refill the tank, taking care not to
exceed the limit. If petrol splashes are to be seen on the moped after refilling, clean these
off immediately.
Use normal lead-free petrol with a RESEARCH 95 octane number.
Fuel tank capacity:
Total: 10 L.
DANGER OF FIRE
Operations that could start a fire.
A
DANGER OF EXPLOSION
Operations that could set off an explosion.
F-11
22
ENGLIS
Rieju chassis
Chassis
COOLANT
Check
1. Remove the radiator cap (A/F-12) with the engine cold and allowing the residual pressure
to escape first.
2. Check the level of coolant with the engine cold, because this will vary depending on the
temperature of the engine. The coolant level should cover the radiator panel.
3. If the level is lower than this, add coolant.
4. Refit the radiator cap.
A
F-12
REPLACING COOLANT
Before performing this operation, place a container under the pipe.
1. Stand the machine on a flat surface and place a container under the radiator.
2. Drain the cooling circuit using the drain screw (A/F-13).
Should a larger than usual amount of coolant be required to reach the indicated level, or if
replenishing needs to be done too often, check all the cooling circuit.
A
F-13
23
Rieju chassis
Chassis
ENGINE OIL
Inside the tank there is an electrical contact that switches on the red reserve warning light
on the instrument panel when the tank is low in oil.
Add oil, remove the cap (A/F-14) and refill carefully.
Recommended oil:
SYNTHETIC OIL FOR 2-STROKE ENGINES.
A
F-14
TRANSMISSION OIL
Change
1. Stand the machine on a flat service.
2. Warm up the engine for several minutes.
3. Stop the engine. Place a container under the engine to catch the oil and remove the filler
cap (C/F-15).
4. Remove the drain plug (A/F-15) and the screw (B/F-15) to let the oil drain out.
5. Replace the drain plug (A/F-15) and tighten it.
6. Fill the engine with oil until it emerges from the level control hole (B/F-15). Replace the
screw in the hole (B/F-15), replace the filler cap (C/F-15) and tighten it.
The use of 820cc of SAE 10W 40 oil is recommended.
Start up the engine and warm it up for a few minutes. While it is warming up, check that
there are no oil leaks. If there are, stop the engine immediately and find out what is causing
the leaks.
C
B
A
F-15
24
ENGLIS
Rieju chassis
Chassis
BRAKE FLUID
Check
B
A
When checking the level of the liquid, turn the
handlebars to check that the top of the main
cylinder is levelled.
Check that the brake fluid is over the minimum level in the rear brake reservoir, and
check that there is enough fluid for the front
brake by looking through the spy-hole in the
cylinder.
MIN
F-16
Change
For the front brake, remove the cover
(A/F-16), having removed the bolts (B/F-16).
For the rear brake, remove the cover
(C/F-17).
C
The quality of the fluid used should conform to
the specified regulations, since otherwise the
rubber seals may deteriorate, leading to leaks
and reducing the efficiency of the brakes.
MIX
MAX
Recommended brake fluid: DOT 4
F-17
ATTENTION: Brake fluid is abrasive.
ADJUSTING THE MINIMUM REV SETTING
Start the engine and warm it up for a few minutes at a rate of 1000 to 2000 rpm, revving
it from time to time up to 4000 to 5000 rpm.
When the engine responds quickly to the
throttle movement, this means that the engine has warmed up.
A
Adjust the minimum revs of the engine by
turning the fuel regulating screw (A/F-18).
Turn the screw to the right to increase the
revs, and to the left to decrease them.
Check the ideal revs for the engine using
an electronic tachometer connected to the
spark plug lead.
F-18
25
Rieju chassis
Chassis
ADJUSTING TRANSMISION CHAIN TENSION
A
30-40 mm
B
F-19
F-20
Checking and adjusting the chain requires adjustment to the rear wheel axle, attempting at
all times to work at the maximum point of chain tension.
To check the play, turn the rear wheel several times and check the tension at various points
to find the tightest point.
The moped should be placed with both wheels on the ground, and chain play should be
between 30 and 40 mm. (F-20)
The chain is adjusted by loosening the rear wheel axle (A/F-19) and screwing the nuts and
bolts (B/F-19) adjacent to the axle in or out, ensuring that there is always the same distance
on both sides of the axle.
Poor alignment of the chain and wheel may cause the chain to detach, as well as problems
with the machine’s stability.
The chain needs to be cleaned and greased periodically. The chain is made up of
a large number of parts that work with each other. If the chain is not properly
maintained, it will wear rapidly, and therefore it is highly advisable to grease it
regularly, using special chain lubricating oil.
Before lubrication, the chain needs to be cleaned to remove the dirt and mud
from the chain, using a brush and cloth, and the lubricant is then applied between the side plates, and on all the central rollers.
26
ENG
Disassembly
27
Rieju chassis
Chassis
1. REAR VIEW MIRRORS
Unscrew the 2 side bolts (A/F-1) and remove
the rear-view mirror from the top.
A
F-1
2. FRONT HEADLIGHT HOLDER
* Remove the rear-view mirrors.
Unscrew the 3 screws (A/F-2) on both sides of the headlight holder.
Then pull out the unit to remove it.
A
F-2
F-3
NAKED version.
B
Unscrew the 2 screws (B/F-4) on both sides.
F-4
28
ENGLIS
Rieju chassis
Chassis
3. FRONT SIDE COVERS
* Remove the headlight holder and the front turn indicator lights.
Unscrew the 2 side screws (A/F-5) and the screw located at the front,
the 2 screws (B/F-6) at the bottom and the 4 screws (B/F-6) on the side of the cover.
B
A
A
F-5
F-6
4. SEAT
Cut the two top straps (A/F-7) on the rear mudguard to access the seat securing bolt.
Then, unscrew the bolt (B/F-8) securing the seat.
A
B
F-7
F-8
29
Rieju chassis
Chassis
5. NUMBER PLATE HOLDER
A
* Remove the rear turn indicator lights.
Unscrew the 4 screws (A/F-9) located at the
bottom.
F-9
6. REAR COVER
*Remove the rider’s seat and the pillion passenger seat.
Unscrew the 4 top bolts (A/F-10), the 2 side bolts (B/F-10)
and the 4 bolts (C/F-11) securing the number plate holder.
Then pull out the unit to remove it.
C
A
B
F-10
F-11
7. FRONT MUDGUARD
Disconnect the speedometer cable (A/F-12) from the control panel and withdraw it through
the hole in the mudguard.
Then unscrew the 2 screws (B/F-12) located at both sides of the mudguard.
A
B
30
F-12
ENGLIS
Rieju chassis
Chassis
8. FUEL TANK
Remove the clips securing the pipe (B/F-14).
Remove the pipes from the tap.
Disconnect the fuel level sensor (A/F-13).
Unscrew the bolt (C/F-15) securing the tank to the chassis.
Then remove the tank by pulling it upwards.
B
A
F-13
F-14
DANGER OF FIRE
Operations that could start a fire.
C
DANGER OF EXPLOSION
Operations that could set off an explosion.
F-15
9. FUEL TANK PROTECTOR
Unscrew the 5 screws (A/F-16) at the top.
Then unscrew the 2 bolts (B/F-17) at the back and remove the protector.
A
B
F-16
F-17
31
Rieju chassis
Chassis
10. HANDLEBARS
* Remove the controls on each end.
Unscrew the 2 side bolts (A/F-18-19) and remove the right and left handlebars.
A
A
F-18
F-19
NAKED version.
B
* Remove the controls on both sides.
Unscrew the 4 screws (B/F-20).
F-20
11. STEERING
Unscrew the 2 bolts (A/F-21) on the sides of
the handlebars.
Extract the top nut (B/F-21) and remove the
top plate.
A
To extract the shaft, unscrew the nut (C/F-21).
B
A
C
F-21
32
ENGLIS
Rieju chassis
Chassis
12. CLUTCH LEVER
C
Disconnect the clutch cable (A/F-22) and the
choke cable (B/F-22).
A
Then unscrew the 2 bolts (C/F-22) and remove the lever.
B
F-22
13. FRONT BRAKE CYLINDER
Disconnect the brake light microswitch terminals.
Unscrew the connector (A/F-23) securing the pipe to the brake cylinder.
Then, unscrew the 2 bolts (B/F-24) and remove the front brake cylinder.
ATTENTION: when reassembling, it is recommended to renew the copper seals and bleed
the circuit.
ATTENTION: Brake fluid is abrasive.
A
B
F-23
F-24
33
Rieju chassis
Chassis
14. FRONT HEADLIGHT
* Remove the front headlight holder.
Disconnect the wires.
Then unscrew the 2 bolts (A/F-25) securing the headlight to the headlight holder.
ATTENTION: Pay attention to the position of the wires, to enable subsequent re-assembly.
A
F-25
NAKED version.
Disconnect the headlight from the general
wiring.
Then unscrew the 2 screws (B/F-26) on the
sides.
B
F-26
15. FRONT INDICATOR LIGHTS
Unscrew the bolt (A/F-27), while holding the nut on the inside.
Then disconnect the light (B/F-28) from the general wiring.
ATTENTION: Pay attention to the position of the wires, to enable subsequent re-assembly.
A
B
F-27
34
F-28
ENGLIS
Rieju chassis
Chassis
16. REAR LIGHT
* Remove the rear cover.
Cut the clip securing the wires and disconnect from the general wiring.
Then loosen the 2 bolts (A/F-30) securing the light to the mudguard.
To extract it, pull the wire to withdraw the light.
ATTENTION: Before proceeding to dismantle the lights, pay attention to the sequence of
the terminals, to enable subsequent re-assembly (see wiring diagram).
A
F-29
F-30
17. REAR INDICATOR LIGHTS
Cut the clip securing the wires (A/F-31) and disconnect from the general wiring.
Then loosen the screw (B/F-32) and pull the wire to withdraw the light.
ATTENTION: Before proceeding to dismantle the lights, pay attention to the sequence of
the terminals, to enable subsequent re-assembly (see wiring diagram).
A
B
F-31
F-32
35
Rieju chassis
Chassis
18. INSTRUMENT PANEL
* Remove the front headlight holder.
Disconnect the speedometer cable (A/F-33).
Then unscrew the 3 bolts (B/F-33) securing the screen to the support.
RS2 MATRIX version.
B
A
F-33
NAKED version.
Disconnect the instrument panel.
Then unscrew the 2 screws.
F-34
19.TURN INDICATOR REGULATOR
Disconnect the regulator from the wiring (A/F-35).
A
F-35
ATTENTION: Remember to reconnect the earth wire when reassembling.
36
ENGLIS
Rieju chassis
Chassis
20. CONTACT RELAY
Disconnect the contact relay (A/F-36) from the general wiring.
Then extract it from the holding rubber.
A
F-36
21. CONTROL UNIT (CDI)
Unscrew the 2 securing screws (A/F-37) and then disconnect from the wiring.
A
F-37
F-38
37
Rieju chassis
Chassis
22. BATTERY
* Remove the pillion passenger seat.
Disconnect the two wires (red positive and black
negative).
Withdraw the securing rubber and then remove
the battery by pulling it upwards.
F-39
23. OIL SENSOR
* Remove the seat and the rear cover.
Disconnect the sensor from the wiring and pull
the sensor upwards to remove it.
F-40
24. OIL TANK
* Remove the seat and the rear cover, and disconnect the level sensor.
Disconnect the pipe from the tank.
Then unscrew the 2 bolts (B/F-41) securing the
tank to the chassis and remove it.
B
F-41
ATTENTION: Before proceeding with the dismantling, drain the oil from the tank.
38
ENGLIS
Rieju chassis
Chassis
25. AIR FILTER
* Remove the seat and the rear cover.
Unscrew the 3 filter cover bolts (A/F-42) and remove the filter.
A
F-42
F-43
26. FUEL TRANSMISSION/OIL MIXER
Unscrew the 2 cover screws (A/F-44).
Pull back the sensor and remove the fuel cable.
A
F-44
F-45
27. “AIS” SYSTEM (Secondary air valve)
Disconnect clips (A/F-46).
Unscrew the 2 securing bolts (B/F-47).
A
B
F-46
F-47
39
Rieju chassis
Chassis
28. EXHAUST
Disconnect the breather pipe (AIS system) (A/F-48) and remove the exhaust pipe by pulling
out forwards.
Remove the 2 springs (B/F-48) securing the exhaust pipe to the engine at the front.
Unscrew the screw (F/F-51) securing the exhaust.
Unscrew the clip (C/F-49) securing the exhaust pipe to the chassis.
ATTENTION: Before proceeding to dismantle the exhaust pipe, make sure it has cooled
down.
B
C
A
F-48
F-49
29. SILENCER
Unscrew the bolt (D/F-50) securing the silencer to the chassis.
Then, Loosen the 3 nuts (E/F-51) securing the silencer to the exhaust pipe.
To extract the silencer, pull it backwards.
ATTENTION: Before proceeding to dismantle the silencer, make sure it has cooled down.
F
D
E
F-50
40
F-51
ENGLIS
Rieju chassis
Chassis
30. RADIATOR
*Remove the front side covers.
Drain the cooling circuit using the drain screw (A/F-52).
Loosen the clips holding the engine and radiator hoses (B/F-53).
Then unscrew the 2 bolts (C/F-54) securing the air inlet and the radiator to the chassis.
B
A
B
F-52
F-53
C
F-54
ATTENTION: Place a container underneath to collect the oil from the tank.
31. CARBURETTOR
Cut the clamp (A/F-55) holding the carburettor
to the filter box.
Unscrew the top cover of the carburettor
(B/F-55) and extract it with the outlet.
In addition, unscrew the bolt securing the cable
to the crankcase (C/F-55) and extract it.
Disconnect the suction hose and the other pipes.
ATTENTION: Pay attention to the position of
the pipes, to enable subsequent re-assembly.
A
C
B
F-55
41
Rieju chassis
Chassis
32. GEAR CHANGE LEVER
Remove the cotter pin (A/F-56) from the rod.
Then unscrew the bolt (B/F-56) securing the gear-change lever to the chassis.
A
B
F-56
33. REAR BRAKE LEVER
Unscrew the 2 bolts (A/F-57) and withdraw the rear brake lever assembly.
A
F-57
42
ENGLIS
Rieju chassis
Chassis
34. SIDE STAND
ATTENTION: Ensure the moped is suitably
secured before performing this operation.
B
Remove the tensioning spring (A/F-58).
Then, unscrew the 2 bolts (B/F-58).
A
F-58
35. REAR BRAKE CYLINDER
Unscrew the 2 bolts (A/F-59) securing the brake
cylinder to the support.
B
Remove the clamp (B/F-59) from the brake fluid
supply pipe and drain it into a container.
A
F-59
ATTENTION: Brake fluid is abrasive.
36. REAR BRAKE CALLIPER
* Remove the rear wheel.
Unscrew the connector using the bolt
(A/F-60).
A
ATTENTION: When reassembling, it is recommended to renew the copper seals and
bleed the circuit.
F-60
43
Rieju chassis
Chassis
37. ENGINE
Disconnect the 2 pipes from the cylinder head heater, unscrew the screws from the suction
pipe (A/F-61) and separate the connector from the spark plug.
Disconnect the heat switch wire.
Disconnect the neutral position wire (G/F-64), located at the bottom of the engine, the
magneto wires and the central unit wires.
Unscrew the screws from the oil mixer cover and disconnect the transmission
(A/F-44) - see page 39.
Drain the cooling circuit using the drain screw (B/F-62).
Disconnect the hose (C/F-62) from the cylinder head to radiator and pump to radiator.
Remove the 2 self-locking nuts and remove the 2 bolts (D/F-63) securing the engine.
Loosen the bolt (E/F-64) and tilt the bracket forwards.
Then remove the self-locking nut (F/F-64) and remove the bolt securing the engine.
ATTENTION: Leave the bottom bolt until last.
C
A
B
F-62
F-61
D
E
F
F-63
44
G
F-64
ENGLIS
Rieju chassis
Chassis
38. REAR WHEEL
Loosen the driving chain and withdrawing it
from the dish of the wheel.
Then unscrew the axle (A/F-65) and to pull it to
withdraw it.
A
F-65
39. CHAIN PROTECTOR
Unscrew the 2 bolts (A/F-66) on both sides
and remove the protector.
A
F-66
40. DRIVE CHAIN
Remove the 2 protector securing bolts (A/F-67) and remove it.
Extract the link securing clip (B/F-68) and remove it.
Chain tensioning (See page 26).
B
A
F-67
F-68
45
Rieju chassis
Chassis
41. SHOCK ABSORBER
* Remove the rear cover.
Unscrew the 2 bolts (A/F-69) securing the shock absorber to the chassis.
Then extract it from behind.
ATTENTION: Before dismantling, secure the chassis at the bottom to prevent the swinging
arm and wheel from falling.
ATTENTION: Pay attention to the position of the shock absorber, to enable subsequent
re-assembly.
A
A
F-69
42. SWING ARM
* Remove the chain, rear wheel, rear brake
calliper and shock absorber.
A
Remove the caps on both sides, unscrew the
nut (A/F-70) and remove the axle from the right
hand side.
F-70
46
ENGLIS
Rieju chassis
Chassis
43. FRONT WHEEL
ATTENTION: Loosen the axle securing bolts
(A/F-71) located on the forks.
Unscrew the axle (B/F-71) from the wheel and
withdraw it.
B
A
F-71
44. FRONT BRAKE CALLIPER
Unscrew the connector using the bolt
(A/F-72).
A
Then unscrew the 2 bolts (B/F-72) securing the
calliper to the front forks.
ATTENTION: When reassembling, it is recommended to renew the copper seals and bleed
the circuit.
B
F-72
45. FRONT BRAKE DISK
*Remove the front wheel.
Unscrew the bolts (A/F-73) securing the disk.
A
F-73
47
Rieju chassis
46. SPEED SENSOR
Chassis
A
Unscrew the bolt and disconnect from of the
other end.
F-74
47. FRONT FOOTRESTS
Remove the clip (A/F-75) and then withdraw
the cotter pin (B/F-75) in order to extract the
footrest.
ATTENTION: Make a note of the position of
the spring to enable subsequent reassembly.
A
B
F-75
48. REAR FOOTRESTS BRACKET
Unscrew the 2 bolts (A/F-76) securing the bracket to the chassis.
A
F-76
48
ENGLIS
Rieju chassis
Chassis
49.TIGHTENING TORQUES
TIGHTENING TORQUE TABLE
Element
N*m
Kg*m
Front wheel bolt
38 - 52
3,8 - 5,2
Front wheel bolt lock
17 - 23
1,7 - 2,3
G
Rear wheel bolt
72 - 98
7,2 - 9,8
G
Front/rear brake calliper
24 - 36
2,4 - 3,6
Silencer
6 - 10
0,6 - 1,0
Exhaust silencer side coupling
6 - 10
0,6 - 1,0
Engine mounting bolts
20 - 26
2,0 - 2,6
2-4
0,2 - 0,4
Shock absorber bolts
38 - 52
3,8 - 5,2
Front wheel bolt
51 - 69
5,1 - 6,9
Handlebar securing bolt
18 - 24
1,8 - 2,4
Top steering nut
18 - 24
1,8 - 2,4
Intermediate steering nut
25 - 34
2,5 - 3,4
Swinging arm bolt
60 - 75
9,0 - 7,5
Handlebar controls bolt
G
Notes
G
G
Gauze
49
ENGLIS
Index
Chassis
ELECTRIC SYSTEM
1. DASHBOARD PROGRAMMING
3
2. ELECTRIC DIAGRAM 2003
5
3. ELECTRIC DIAGRAM 2006
6
1
ENGLIS
Electric system
Chassis
1. DASHBOARD PROGRAMMING
DASHBOARD
The dashboard contains two buttons in its right side, the upper one is to select “SET” and
the lower one for the function “MODE.”
SET THE CLOCK
• Put the key in the IGNITION position, with the engine turned off.
• Wait three seconds and the INITIAL screen will appear on the DISPLAY.
• Press the button “Mode” for 6 seconds, and the digit to be selected (hours) will be
flickered.
• With the button “Set”, select the suitable number.
• Once the hour is selected, press the button “Mode” again and the digits corresponding
to the minutes will be flickered.
• Select with the button “Set” and press the button “Mode” again turning back to the
Initial screen.
INSERTION OF THE PARAMETERS OF CALCULATION IN THE ODOMETER
MEMORY
• Development of the wheel that sets the signal sensor.
• Pulses of the signal sensor.
• Pulses of Revolutions.
Put the key in the IGNITION position with the engine turned off.
• Wait three seconds and the INITIAL screen will appear on the DISPLAY.
• Press the button “MODE”, and without releasing it, press the button “SET” for one
second, automatically the word “SET” will be displayed on the screen to be able to
insert the values.
3
Electric system
Chassis
• The first value is the development of the wheel and it should be inserted in mm.
• Pressing the button “SET” we select the digit, and with the button “MODE” pressed
for three seconds we pass to the next digit, and using this sequence we insert the fixed
development to that wheel.
• Keeping the button “Mode” pressed for 3 seconds, the screen of the Display will
request us for the pulses, with the word “PULSE”, following the sequence insert the
value.
• We keep the button “Mode” pressed and the option of miles, (mph) and kilometres
hour (km / h) will be displayed, then we will choose km / h with the button “SET”.
• Following the sequence, the word “PULSE” will appear on the screen and above it
“RPM”, we will insert the value corresponding to the RPM.
Keeping the button “MODE” pressed for 3 seconds more, we will turn back to the INITIAL
screen.
TO CHECK IF THE INPUT DATA IS THE RIGHT ONE, WE SHOULD TURN ON THE
IGNITION, START THE ENGINE AND IN TWO SECONDS THE ENTERED DATA WILL
BE DISPLAYED ON THE SCREEN DURING TWO SECONDS, VERIFYING THAT IT IS
CORRECT, IMMEDIATELY AFTER THE INITIAL SCREEN WILL APPEAR.
The dashboard is ready to be used giving the right information.
SET OF VALUES
VALUES TO BE INSERTED IN THE DISPLAY CONFIGURATION
RS2 50 cc. MATRIX
RS2 50 cc. MATRIX PRO
Rear Tyre
Circumference Wheel
4
130/70-17
1930
Pulses of the Sensor (screws)
5
Pulses of RPM
3
ENGLIS
Electric system
Chassis
2. ELECTRIC DIAGRAM 2003
0/000.160.7000/7004
5
Electric system
Chassis
3. ELECTRIC DIAGRAM 2006
0/000.160.7008/7009
6
ENGLIS
Index
Engine
INTRODUCTION
NOTES FOR EASY CONSULTATION
6
GENERAL WORK PROCEDURES
7
RECOMMENDATIONS
8
SPARK PLUGS
10
ENGINE RIEJU
EQUIPMENT KIT
14
LUBRICANTS
14
ENGINE DISASSEMBLY
15
MAINTENANCE
22
ENGINE ASSEMBLY
26
ENGINE SERVICINGAND COMMISSIONING SCHEDULE
33
PARTS AND THEIR TORQUE WRENCH SETTINGS
34
EXPLODED VIEW OF THE ENGINE AM6 EURO2
35
1
ENG
Introduction
3
Introduction
Engine
• All checks, maintenance, repairs or replacements, etc. on the vehicles manufactured by Malaguti are to be performed by skilled and expert technical personnel with specific experience in state-of-the-art technology and full knowledge of the quickest and most rational procedures, technical
characteristics, setting values and tightening torques, which may only be properly and exhaustively
provided by the manufacturer.
• This set of WORKSHOP MANUALS concerning two-stroke engines provides technicians of
the sector (Authorised Service Centres, etc.), the essential information for operating in accordance
with the latest good working practices and work safety regulations.
• These publications provide all necessary information for routine procedures on all the RIEJUmotor vehicles equipped with two-stroke engines currently in production at the date of issue. The
information provided deals with the motor vehicle ENGINES. Some basic technical information has
been intentionally omitted as it is considered to be common knowledge.
• Additional information is available in the SPARE PARTS CATALOGUES of each model.
• It is important that before referring to the specific engine manual, the information given in this
general section be carefully read as it provides all the essential hints and guidelines for best consulting
the various topics and main technical subjects.
Note:
These manuals provide the necessary information and instructions for routine maintenance
and servicing. This information has been given to us by the engine manufacturers. We therefore
decline all responsibility for any error, omission or misrepresentation. RIEJU reserves the right
to make any changes and modifications hereto it deems necessary without prior notice.
For further information and details, please contact the RIEJU, S.A. Service Division.
1.1 MANUAL UPDATES
• The updates will be sent by us ( in a reasonable time). Every Cd-Rom you will receive, will supersede the one already in your hands.
• The table of contents will be duly updated in the event that new pages are inserted, which render the consultation of the manual difficult.
• IMPORTANT! The Workshop Manuals are to be considered as essential tools to be properly
kept up-to-date so as to maintain their “ validity” over time.
4
ENGLIS
Introduction
Engine
EDITING SYMBOLS
CAUTION! Recommendations and precautions regarding rider safety and
motor vehicle integrity.
WARNING!
Situations entailing the risk of personal injury to maintenance or repair mechanics, other workshop personnel or third parties, or damage to environment,
vehicle or equipment.
FIRE HAZARD
Indicates operations which may constitute a fire hazard.
RISK OF EXPLOSION
Indicates operations which may constitute a risk of explosion.
C
IC
OXXI
TTO
TOXIC
Indicates a possibility of intoxication or inflammation of the upper respiratory
tract.
MECHANICAL MAINTENANCE
Operations to be performed only by an expert mechanic.
ELECTRICAL MAINTENANCE
Operations be performed only by an expert electrical / electronic technician.
NO!
Operations to be absolutely avoided.
ENGINE SERVICE MANUAL
Indicates information which may be obtained by referring to said manual.
SPARE PARTS CATALOGUE
Indicates information which may be obtained by referring to said catalogue.
5
Introduction
Engine
F
Pr Tr
Figure
Tightening torque
P
Ap
S
Page
Paragraph
Section
Es
T
Diagram
Table
Tr
Screw
Note:
The letter Tr in the illustrations refers to retaining or adjusting screws.The
number following this letter refers to the number of the same type of screw
in the unit or component described and illustrated. Letters not followed by
a number indicate a single screw . In case of different screws being referred
to in the illustration, the letter Tr is followed by a number and a small letter
, for instance: (Tr4a).
Unless otherwise specified, units and components are reassembled by proceeding in the reverse order of removal.
OPERATIONAL SYMBOLS
L) Loctite
L
O) Oil lubrication
O
G)
6
Greasing
G
ENGLIS
Introduction
Engine
1.3 GENERAL WORK PROCEDURES
• The advice, recommendations and warnings given hereafter are aimed at ensuring
maximum work safety as well as at considerably reducing the risk of accidents, personal
injury, equipment damage and idle times. They should therefore be strictly adhered to.
ADVICE:
• Only use quality tools and equipment.
• Only use equipment conforming to EU Directives for lifting the vehicle.
• During operations, always keep tools and equipment at hand, possibly laying them out
according to the sequence in which they are to be used. Absolutely avoid putting them on
the vehicle itself, out-of-sight or in poorly accessible places.
• Always keep the work area clean and tidy.
•When tightening screws or nuts, start with the larger diameter or inner fasteners, and
tighten them in progressive “pulls” in accordance to a “criss-cross” pattern.
• Preferably use open-end box wrenches by “pulling” and not “pushing”.
• Adjustable wrenches (F-1) should only be used in case of emergency, i.e. when a properly
sized wrench is not available. They should preferably not be used as the movable jaw tends
to open thus risking damaging or not properly tightening the bolt to the correct torque. In
any case, when using an adjustable wrench, take care to proceed as shown in Figure 1.
• Except for occasional customers, always make out and deliver to the customer a work
sheet specifying the operations performed, with notes as to any future checks eventually
required.
F-1
7
Introduction
Engine
1.4 WARNINGS
• Before carrying out any operation on the vehicle, wait for all parts to cool down.
• For operations requiring two mechanics, make sure that the various steps to be performed
by each of them are clearly defined and coordinated beforehand.
• Make sure that each component has been properly fitted before proceeding with the next
one.
• Lubricate all parts (where applicable) before reinstalling them.
• Gaskets, O-rings, circlips and split pins must be replaced at every refitting.
• The torque settings specified in the manuals refer to the “final torque”, which must be
attained progressively by steps.
• Loosen and tighten aluminium alloy parts (covers) only after the engine has fully cooled
down.
• Only use screwdrivers with sizes suitable to the screws to be loosened or tightened.
• Work in a comfortable position and ensure that the vehicle is stable.
• Never use a screwdriver as a lever or chisel.
• Never use pincers to loosen or tighten screws or nuts because, in addition to
not providing a sufficient clamping force, they may also damage the screw head
or nut hexagon.
• Never tap the wrench with a hammer or other similar tools to loosen or tighten screws and nuts (F-2).
• Never attempt to increase the lever arm by fitting a tube into the wrench (F3).
F-2
8
F-3
ENGLIS
Introduction
Engine
Never use open flames for any reason.
Never leave open containers or containers not suitable for holding fuel in passageways,
close to heat
sources, etc
Never use petrol to clean the vehicle or the floor of the workshop. Always use low flash
point solvents to clean the vehicle components.
Never suck from or blow into the fuel pipe.
When welding, make sure that there are no flammable liquids in the vicinity. Always remove the tank, even if completely empty, and disconnect the negative cable (-) from the
battery.
Never leave the engine running in closed or poorly ventilated areas.
Before any servicing, make sure that the motorbike is perfectly stable.
The front wheel should preferably be anchored to the equipment (A/F-4) integral with the
lifting board.
F-4
9
Introduction
Engine
1.5 SPARK PLUGS
1. Insulator
2. Body
3. Gasket
4. Electrode
5. Earth electrode
6. Threads
F-5
SPARK PLUG CHECK
1,000 km
• Remove the spark plug while the engine is hot ( taking utmost care to avoid
scalding!).
• The carbon deposits and the colour of the insulator ( around the central
electrode) provide good information as to the heat range of the spark plug
and to carburetion, lubrication and general condition of the engine.
• A light brown colour of the insulator indicates that engine working conditions are generally correct.
• Sooty black deposits, that are dry ( to the touch) and opaque, are a sign that
working temperature is too low, i.e. that the heat range of the spark plug is
too high, mixture too rich or ignition defective.
•A whitish colour of the insulator is indicative of too lean a mixture or of too
low a heat range of the spark plug (i.e. spark plug too “hot”).
• Check electrode gap (F-6) (even if the spark plug is new) by means of a
calibrated thickness gauge. If necessary, adjust by acting only on the earth
electrode.
Pr Tr - Nm
20 - 25
F-6
10
ENGLIS
Introduction
Engine
SPARK PLUG MAINTENANCE
• Spark plug maintenance consists essentially of a periodical visual inspection. Remove the
spark plug and check for proper condition and gap.
• Clean the electrodes and the insulator thoroughly by means of a wire brush.
• Remove any residual dirt with a strong jet of compressed air.
• Lubricate spark plug thread with engine oil or graphitised grease, and install it by hand until
finger tight.
Tighten to the specified torque with a spark plug wrench (see F-6).
It is imperative that any spark plug exhibiting cracks on the insulator or corroded electrodes be replaced.
SPARK PLUG REPLACEMENT
5000 km
• Upon prescribed mileage being reached, always replace the spark plug. Use RIEJU,
S.A. recommended spark plugs.
• When replacing exhausted spark plugs, visually inspect spark plug condition as described
above to ascertain whether or not the engine is running properly.
ENGINE REMOVAL
• For removal of the engine from the chassis, refer to the “Chassis” Workshop Manual,
which lists all the operations required.
ENGINE DISASSEMBLY
The manufacturer declines all responsibility for damage of any kind caused by
disassembly and reassembly of the engine and its parts if unsuitable tools are
used.
Use only ORIGINAL RIEJU SPARE PARTS.
11
ENG
Engine RIEJU
13
Engine Rieju
2.1 EQUIPMENT KIT
Code RIEJU 0/000.640.9999
2.2 LUBRICANTS
LUBRICANTS TABLE
LUBRICANTS FOR TWO-STROKE ENGINE
1) Synthetic mix oil
2) Gearbox oil SAE 10W30, type SE
GENERAL PURPOSE LUBRICANTS
3) Grease for moving parts
14
Engine
ENGLIS
Engine Rieju
Engine
2.3 DISASSEMBLY OF THE ENGINE
After removing the spark-plug and carburettor proceed as follows:
1) DRAIN the engine oil by removing the relevant drain bolt.
ESPAÑOL
2) UNSCREW the coolant drainage screw (1/F-1); remove the water pump cover by undoing the two fixing screws (2/F-1). Pay attention to the dowel bolts (1/F-2).
F-1
F-2
3) UNDO the fixing screws of the flywheel cover (left hand side) and remove it.
Remove the starter motor (if fitted) by removing the two screws on the crankcase and the
screw on the support strap.
4) Take the carburettor out of its seat; remove the intake union and the relative clutch “bridge”; remove the plate group (1/F-3).
5) REMOVE the sprocket (1/F-4) by removing the snap ring (2/F-4); using ring pliers, remove
the sprocket by hand and remove the other snap ring underneath the sprocket.
F-3
F-4
15
Engine Rieju
Engine
F-5
F-6
6) REMOVE the sliding stop screw for starting from clutch side (1/F-5).
7) REMOVE the fixing screws of the plastic oil pump cap (1/F-6). Undo the screws securing
the oil pump to the cover; then remove the pump.
F-7
F-8
8) REMOVE the cover/crankcase fixing screws (of which one M6x55 (2/F-6), that secure
the water pump cover and the relative clutch cover to the crankcase); now remove the
cover (3/F-6) and its gasket.
9) TAKE the starter assembly OUT of its seat (only for versions with starter pedals),
bearing in mind that the any shim washers must be put in the same position when the component is reassembled.
CAUTION: when disassembling this group, carefully check the position of the
pieces so as to reassemble them correctly afterwards.
10) UNDO the screws compressing the clutch springs (1/F-7); then remove the clutch plate (2/F-7) and the entire set of discs (3 /F-7); remove the disc pusher, the ball and the clutch
rod (1, 2, 3/F-8), which are housed in the centre hole of the change shaft.
16
ENGLIS
Engine Rieju
F-9
ESPAÑOL
Engine
F-10
11) DISENGAGE the nut from its fixing tab (1/F-9); using the appropriate wrench
(1/F-10), unscrew and remove the fixing nut (2/F-10) of the clutch boss.
12) REMOVE the following pieces in this order: clutch boss (1/F-11), spacer (2/F-11), clutch
gear (3/F-11), shim washer (1/F-12), tapered washer (2/F-12), paying attention to the direction in which they are assembled so as to reassemble them correctly afterwards.
F-11
F-12
13) USING the magneto flywheel locking wrench (1/F-13), lock the flywheel and slacken
the retaining nut of the gear on the countershaft with the wrench (1/F-14).
14) REMOVE the gear on the countershaft (1/F-14) and the key.
F-13
F-14
17
Engine Rieju
Engine
15) UNSCREW the nut (2/F-14) with a 19 mm wrench, whilst holding the flywheel in
place with the special wrench; then remove the following parts in this order: drive pinion,
countershaft drive gear, key, spacer bushing and O-ring.
16) BLOCKING the rotor of the magneto flywheel with the special locking wrench
(1/F-15), unscrew the rotor retaining nut with a 15 mm wrench.
F-15
F-16
17) REMOVE the rotor of the magneto flywheel by means of the appropriate puller
(1/F-16), which must be screwed into the threaded seat of the rotor; whilst holding the
latter in place with a wrench, turn the centre screw.
18) REMOVE the stator by undoing the screws that secure it to the plate (1/F-17).
19) TAKE the stator plate OUT of its seat by removing the 3 screws that secure it to the
crankcase (2/F-17), and remove the key (3/F-17).
F-17
18
ENGLIS
Engine Rieju
Engine
F-18
ESPAÑOL
20) DISASSEMBLING the thermal section:
a) unscrew the 4 cylinder head holding nuts and remove the relevant washers; remove the
head, its O-ring, the cylinder, the cylinder gasket and the four O-ring on the stud bolts.
F-19
CAUTION: before removing the circlips of the piston pin, put a clean cloth
into the opening on the crankcase, to prevent the circlips dropping into the
engine.
21) REMOVE the two circlips (F-18), remove the piston pin and, if you intend to use a 2diameter plug, knock gently taking care to hold the piston on the opposite side in order to
avoid damaging the connecting rod.
22) REMOVE the 13 screws joining the two crankcases (F-19) and take the clutch pin out
of its seat.
F-20
F-21
23) SEPARATE the 2 crankcases by gentling tapping the secondary shaft and shift shaft
with a wooden mallet.
IMPORTANT: if you need to take the crankshaft out of its seat, use the special tool (1/F-20).
24) Once the crankcases have been separated, CHECK that the shim washers are on the
shafts and not on the crankcase that has just been removed (F-21).
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Engine
25) PUT the neutral signal pin in the position shown in the photo (F-22), hence remove the
shift shaft and its relevant lower shim washer (1/F-23).
F-22
F-23
26) PULL OUT the fork guiding rod and remove the top fork (F-24); to take the fork out
of its seat, remove the desmodronic shaft (F-25) and raise the gear on the secondary shaft
carrying the forks.
F-24
F-25
27) PUT the following components TOGETHER:
output shaft, secondary shaft and remaining fork and
raise (F-26), paying attention to the shim washer under the secondary shaft.
28) REMOVE the equaliser countershaft: pull the
connecting rod from the crankcase on clutch side; if
necessary tap gently with a plastic or rubber mallet,
paying attention not to damage the thread.
N.B.: as far as the clutch crankcase side is
concerned, the crankshaft and countershaft
do not interfere with each other.
29) Bearings should only be REMOVED if they
need to be replaced, i.e. they are worn or their service life has ended.
20
F-26
ENGLIS
Engine Rieju
Engine
F-27
ESPAÑOL
30) IF the oil pump needs to be replaced, proceed as follows (F-27):
a) Detach the oil pump supply pipe (1) and put a plug into it to prevent oil leaks.
b) Detach the oil delivery pipe leading from the pump to the carburettor (2).
c) Disconnect the control cable fastened to the pump’s lever (3).
d) Undo the pump fixing screws (4) and remove the pump.
e) Fit the new pump in its seat and replace the O-ring.
f) Plug the oil delivery pipe (2) into the new pump.
g) Plug the oil supply pipe (1) into the pump.
h) Take the purge screw and gasket off the pump (5) and let the oil containing air bubbles
leak out. Wait until only oil is leaking out. Purging can thus be considered accomplished. You
can now refit the screw in place.
I) Reconnect the control cable (3) to the pump lever, making sure that the idle position of
the throttle grip on the handlebar corresponds to the idle position of the lever; otherwise,
make any necessary adjustments by means of the adjustment screw.
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2.4 MAINTENANCE
GENERAL WARNINGS
Before reassembling the engine either totally or partially, thoroughly clean the parts by
washing them with petrol, drying them with compressed air and making sure that they
are sufficiently oiled and in perfect working order.
It is always advisable to replace the gaskets because old ones may be leaky. We recommend you always replace the engine oil seals: they may have been damaged during disassembly and this could adversely affect engine operation. Always use the special plugs to
ensure correct assembly of the oil seals.
A) Secondary gear shaft oil seal:
- Secondary gear shaft oil seal assembly plug.
B) Connecting rod oil seal:
- Connecting rod oil seal assembly plug, clutch side.
- Connecting rod oil seal assembly plug, flywheel side.
C) Clutch lever oil seal:
- Clutch lever oil seal assembly plug.
D) Shift shaft oil seal:
- Shift shaft oil seal assembly plug.
E) Water pump oil seal:
- Water pump oil seal assembly plug.
Check carefully that the pieces are whole and arrange all the various groups
of gears in such a way that assembly may be carried out correctly.
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ENGLIS
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Engine
PREVENTIVE CARE
1) WASH the two crankcases and the bearings with petrol and blow them with compressed air, checking that the bearings run freely and noiselessly.
CAUTION: if it should be necessary to replace a bearing, the seat must be
heated before installing the new bearing.
ESPAÑOL
2) MAKE SURE the connecting rod is in perfect working order and check for faults, especially in the bearing seats. Make sure assembly on flywheel side has been properly accomplished. Using a comparator, check the eccentricity of the two connecting rod axle shafts. The
maximum eccentricity value must not exceed 0.04 mm. On the contrary, centre accordingly.
Make sure the connecting rod is perpendicular.
3) MAKE SURE the transmission is in perfect working order and fit the shim washers in
the right positions. If you have replaced components, make sure that they are put in the
same positions as the parts removed and that the end float does not exceed 0.1 mm. To
obtain this condition, measure the distance of the shim washers on the crankcase and components, and fill any gaps with other shim washers, as shown in the photo (F-28).
4) CHECK the distance of the shim washer of the desmodronic shaft both on the crankcase
and on the part, and fill any gaps with other shim washers, as shown in the photo (F-29).
The end float must be less than 0.1 mm.
F-28
F-29
5) CHECK the distance of the shim washers of the shift shaft both on the crankcase and
on the part, and fill any gaps with other shim washers, as shown in the photo (F-30). The
end float must be less than 0.1 mm.
F-30
F-31
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6) ENSURE that the clutch assembly is in working order.
To do so, ensure that the iron discs are in good condition, that the notches on the cork discs
are not too deformed and that their coating is not burnt. Check that the grooves on the
clutch boss are not too deeply marked; perform the same check on the slots of the clutch
housing. Also check that the clutch springs are not shorter than the permissible
threshold of 29.5 mm (F-31); if they are shorter replace them.
7) CAREFULLY clean the carbon crust from the piston top by means of a common scraper, taking care not to damage the piston itself. Check the piston skirt for streaks or seizing.
Check that it is firmly mated to the lubricated piston pin, the surface of which must be in
perfect condition. Make sure that the piston pin can be fitted by manual pressure and that it
does not yield under its own weight.
8) CHECK the piston rings for faults of any type and make sure that the clearance between
the two ends is within the values shown in the chart.
RINGS
DISTANCE
New
0,15 ÷ 0,30 mm
Used
Up to 1,2 mm
The checks must be carried out using a feeler gauge. The piston ring must be placed in the
cylinder in a horizontal position (F-32).
9) CHECK that the cylinder water jacket does not have seizing notches or wear and that
there is no scoring of any kind. By means of a bore gauge, check the cylinder bore in two
directions at 90° the one from the other (one parallel and the other perpendicular to the
axis of the piston pin) (F-33). The maximum permissible ovalisation is 0.03 mm, exceeding
which the cylinder must be replaced.
F-32
24
F-33
ENGLIS
Engine Rieju
Engine
Repeat the measurements in several positions along the cylinder jacket, between the top
face of the cylinder and the exhaust gap (F-34).
Then check the diameter of the piston and compare it with that of the cylinder (F-33).
F-34
ESPAÑOL
POSITION THE THERMOSTAT
HOLE , ASSHOWN
F-34
The maximum end float is 0.10 mm, exceeding which, the piston should be replaced. See
the chart below.
COUPLING CHART
ENGINE TYPE
AM6 50 (WATER COLLED)
MIN/MAX PLAY
0.049
(CYLINDER IN GHISA)
(CAST IRON CYLINDER)
TOLE. PISTON
TOLE. CYLINDER
SELECTION
-0,063 -0,057
-0,007 -0,002
Y
-0,056 -0,050
-0,001 -0,006
Z
-0,049 -0,043
-0,007 -0,012
V
0.062
Important: maintain the same identification letters on the cylinder and
piston. The cylinder identification letter
can be found on the flat surface of the oiler.
10) WATER PUMP
a) Place the clutch crankcase (right hand side) on a flat surface.
b) Fit the oil seal in the right direction, as shown (F-35).
c) Fit the impeller, gasket, dowels and water pump cover.
F-35
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2.5 ENGINE REASSEMBLY
G
1) PLACE the clutch crankcase (right hand side) on a flat surface. Then, fit the spring and
the gear selection poppet ball in their seats and apply grease to prevent them falling out.
2) PREPARE the transmission assembly (primary/secondary) keeping all components together (F-36). Put a 0.6 mm shim washer under the 1st speed gear and position the fork in
the 3rd and 4 th primary gear (F-36).
LOWER the assembly thus formed into its seats (F-37).
Raise the 5th speed gear on the secondary shaft and insert the fork (F-38).
Fit the other fork (6 th speed gear) into its seat (F-39).
26
F-36
F-37
F-38
F-39
ENGLIS
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Engine
3) FIT the desmodronic shaft (F-40). Insert the fork guide pins into the desmodronic shaft
(F-41).
Fit the fork guide rod into its seat (F-42).
Turn the desmodronic shaft until it reaches the position shown in the figure (F-43).
ESPAÑOL
N.B.: these operations must be effected without forcing (with a hammer or
other tools).
F-40
F-41
F-42
F-43
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4) INSERT the shift shaft with the lower washers (0.6 mm thick) (1/F-44) and insert the
return spring hooks in the relevant anchoring bridge (F-45) then check that:
- By putting the desmodronic shaft in 3rd speed, make sure the rollers of the cam are at
an equal distance from the fork hooks. On the contrary, slightly bend the ends of the
spring until obtaining the requested condition.
F-44
F-45
5) FIT the countershaft in the clutch crankcase.
N.B.: assembly of the countershaft in its seat implies no interference.
6) If it has been removed, FIT the connecting rod in the crankcase on flywheel side
using the tool (1/F-46); keep the connecting rod at the T.D.C. whilst tightening the screw,
until the connecting rod touches the bearings.
7) FIT the dowel bolts (1-2/F-47), apply gasket paste on the mating sides of the crankcases
(F-47) and oil all shafts. Place the crankcase (flywheel side) over the other crankcase and tap
gently all over with a wooden, leather or plastic mallet until the crankcases are joined.
F-46
F-47
8) FIT the 13 fixing screws and tighten in place (Cs 1.0 ÷ 1.2 kg*m). Make sure all shafts
can turn freely. Make sure that none of the shafts feature excessive end play, in which case,
separate the crankcases and replace the top shim washer with another having a more suitable thickness.
9) FIT the new oil seals, using the specific plug for each.
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ENGLIS
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10) FIT the key for the magneto flywheel; put the stator in its seat and fasten in place with
the fixing screws (Cs 0.25 ÷ 0.3 kg*m). Fit the rotor and tighten the nut (Cs 4.3 ÷ 4.5
kg*m), using the usual wrench (F-48).
F-48
ESPAÑOL
11) FIT the sprocket: snap ring (1/F-49) - sprocket (2) - snap ring (1) - fit the clutch control
pin (3/F-49) with its return spring (4/F-49).
F-49
12) CHECK operation of the sprocket and gear wheel pair.
If any of the gears needs to be replaced, it is recommended to replace the pair since this will
ensure smoother and quieter operation.
13) FIT the crankshaft (clutch side) in the following order:
1) The overturned oil seal (1/F-50), using the special plug (2/F-50)
2) The O-ring (1/F-51)
3) The spacer (2/F-51), with the bevelled side facing the crankshaft. Push in place until
it stops.
L
Now fit the key (1/F-52), the countershaft drive gear (2/F-52), the drive sprocket and the
nut (Cs 6.7 ÷ 7.5 kg*m). Fit the key and driven gear on the countershaft (2/F-53), making
sure that the reference notches on the two gears match (F-53). Tighten the nut (Cs 4.5 ÷
5.0 kg*m) (apply Loctite 242).
F-51
F-50
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F-53
F-52
14) PROCEED in reverse order. Refit the clutch assembly and remember to replace the
nut fixing washer with a new one; fit the clutch boss fixing nut (Cs 5.5 ÷ 6.0 kg*m) and
bend the tab.
15) FIT the following components on the output shaft, in the order given: clutch rod (grease beforehand), ball and disc pusher.
16) FIT the clutch disc assembly in the order shown in (F-54); the iron discs (1-2-3/F-54)
should be fitted with the notch, highlighted by the arrows, at 120° the one from the other,
starting from the notch facing upwards on the first disc. Fit the last clutch disc, making sure
it is timed with the boss (F-54b).
F-54
F-55
30
F-54b
ENGLIS
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Engine
17) FIT the springs and fixing screws and tighten (Cs 0.3 ÷ 0.5 kg*m).
18) Correct operating position of the clutch is obtained when the lever, in the position
indicated by the arrow (F-55), is parallel to the cover resting surface.
To obtain this condition, turn the adjustment screw (1/F-56) on the last disc, using the special wrench (2/F-56). Tighten the nut (Cs 2.6 ÷ 2.8 kg*m) .
ESPAÑOL
19) BEFORE fitting the starter assembly (version without an electric starter), make sure
that the phase between the pawl on the sliding rod and the hole for fixing the spring is the
same as before disassembly (90° - F-57).
20) FIT the starter assembly, whilst hooking the spring to the hub on the cover.
F-56
F-57
21) FIT: the dowel bolts and a new gasket on the crankcase; the clutch cover; if necessary,
this operation can be made easier by turning the impeller of the water pump. Secure in place
with screws (Cs 1.0 ÷ 1.2 kg*m).
If you have disassembled it, refit the oil pump, making sure that the O-ring is in working
order (1/F-58a).
When refitting, take care not to damage the oil pump gear.
Whilst fitting the starter lever on its shaft, turn it 180° counter-clockwise and secure in
place with the fixing screws (Cs 2.9 ÷ 3.0 kg*m) (F-58b).
This operation must be performed to pre-load the return spring.
F-58a
F-58b
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22) Before assembly, CHECK the condition of the cage on the piston pin and its rollers.
Fit the piston, making sure that the arrow marked on the top is facing towards the exhaust side (F-59), and therefore towards the piston pin and its circlips.
F-59
F-60
23) In the order indicated, FIT the piston rings, making sure that the ends are correctly
positioned in the seats on the piston; a new cylinder gasket; the cylinder; the centre cylinder
O-ring in the stud bolts; the O-ring on the cylinder head; the head (clean beforehand). Tighten the nuts evenly and diametrically (Cs 1.4 ÷ 1.6 kg*m); check the position and tightness
of the O-ring on the cylinder head.
24) FIT the reed valve (F-60), followed by the exhaust manifold, tightening the four screws
evenly and diametrically (Cs 0.9 ÷ 1.1 kg*m).
25) REFIT the flywheel cover, a new gasket and its fixing screws, which must be tightened
(Cs 0.1 ÷ 0.2 kg*m).
26) REFIT the oil drainage bolt, replace the gasket and secure firmly in place (Cs 1.7 ÷ 1.8
kg*m).
27) POUR oil into the engine (0.750 kg) through the hole at the top.
32
ENGLIS
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2.6 ENGINE SERVICING AND COMMISSIONING SCHEDULE
MAINTENANCE OPERATIONS
AFTER 1000 KM
OR 3 MONTHS
EVERY
5000 KM
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Adjustment of engine idling speed
Gas and oil pump control
Front and rear brake control
Operation of the electrical equipment
Petrol ducts
Oil ducts
Front and rear brake liquid ducts
Coolant duct
Fuel heating duct
Tire pressure
Tire condition, pressure and wear
Level of front and rear brake liquid
Level of coolant
Level of battery electrolyte
Screw tightness
Battery charge level
ESPAÑOL
Check
X
X
X
X
X
X
X
X
X
X
Replace
Air filter filtering element
Front and rear brake pads
Gearbox oil
Chain - pinion - gear wheel
Clutch discs
Spark plug
X
X
X
X
X
X
X
Check and/or replace
Piston
Cylinder head
Discharge gap
every 10.000km
every 10.000km
every 10.000km
Check and lubricate
Chain tightness and condition
X
X
X
X
X
X
X
X
Check and adjust
Clutch control
Oil pump control
Headlinght height
Clean and adjust
X
Carburettor
Vehicle test
Road test
X
X
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2.7 PARTS AND THEIR TORQUE WRENCH SETTINGS
PART POSITION
SCREWS
TORQUE SETTING
N*m
Kg*m
QTY.
14 x 1.25
20÷25
2÷2,5
1
M7 x 1
14÷16
1,4÷1,6
4
Pipe fitting
M8 x 1.25
24÷26
2,4÷2,6
1
Cylinder head
Temperature probe
M14 x 1.25
16÷20
1,6÷2,0
1
5
Countershaft
Hex. nut
M12 x 1
45÷50
4,5÷5,0
1
6
Water cooling (head)
T.C.B. screw
M4 x 0.7
2,5÷3,5
0,25÷0,35
2
7
Water pump body
T.C.C.E. screw
M6 x 1
4÷6
0,4÷0,6
1
8
Pipe coupling
T.C.C.E. screw
M6 x 1
4÷6
0,4÷0,6
1
9
Water pump body
T.C.C.E. screw
M6 x 1
4÷6
0,4÷0,6
1
10
Water pump body
T.C.B. screw
M6 x 1
4÷6
0,4÷0,6
1
11
Oil pump
T.C.C.E. screw
M5 x 0.8
6÷8
0,6÷0,8
2
12
Oil pump lid
T.C.C.E. screw
M5 x 0.8
3÷4
0,3÷0,4
2
13
Intake manifold
T.C.C.E. screw
M6 x 1
9÷11
0,9÷1,1
4
14
Crankcase
Stud bolt
M7 x 1
10÷12
1,0÷1,2
4
15
Cover, clutch side
T.C.B. screw
M6 x 1
2÷4
0,2÷0,4
1
16
Crankcase, flywheel side T.C.C.E. screw
M6 x 1
10÷12
1,0÷1,2
13
17
Crankcase, clutch side
Hex. screw
M8 x 1.25
17÷18
1,7÷1,8
1
18
Crankcase, flywheel side
Neutral indicator light
M10 x 1.25
1÷2
0,1÷0,2
1
20
Crankcase, clutch side
Hex. screw
M12 x 1.25
24÷26
2,4÷ 2,6
1
21
Cover, clutch side
T.C.C.E. screw
M6 x 1
10÷12
1,0÷ 1,2
7
22
Cover, flywheel side
T.C.C.E. screw
M5 x 0.8
1÷2
0,1÷0,2
5
23
Primary gear (Clutch side) Nut
M12 x 1.25
65÷75
6,5÷7,5
1
24
Clutch boss
Hex. screw
M12 x 1.25
55÷60
5,5÷6,6
1
25
Disc boss (clutch)
T.C.C.E. screw
3÷5
0,3÷0,5
4
26
Disc pusher (clutch)
Hex. nut
M14 x 1.25
26÷28
2,6÷2,8
1
Clutch adj. screw
M14 x 1.25
1
Spark plug
Spark plug
2
Cylinder head
Nut
3
Cylinder head
4
27
34
PART NAME
28
Selector
Hex. nut
29
Magneto flywheel
Screw
30
Magneto flywheel
Hex. nut
M5 x 0.8
M7 x 1
M4 x 0.7
M10 x 1.25
turn until it stops
1
14÷16
1,4÷1,6
1
3÷4
0,3÷0,4
3
43÷45
4,3÷4,5
1
O
O
O
L
ENGLIS
Engine Rieju
Engine
ESPAÑOL
2.8 EXPLODED VIEW OF THE ENGINE AM6 EURO2
35
RIEJU, S.A. c/.Borrassà, 41
Telf. +34 / 972500850 Fax +34 / 972506950
E-17600 FIGUERES, GIRONA (SPAIN)
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